Electrical relays



y 5, 1953 w. B. WELLS ETAL 2,833,885

ELECTRICAL RELAYS Filed Oct. 25, 1954 2 Sheets-Sheet 1 1 llzsalaion INVENTORS. Wesley B. Wlls and Russell H. Adkins BY 6 -4 W- THEZR ATTORNEY y 1958 w. B. WELLS ETAL 2,833,885

ELECTRICAL RELAYS Filed Oct. 25, 1954 2 Sheets-Sheet 2 .w y i INVENTORS. L Wesley B Wblls and fussell M Adkin? [a]. A dial,

THEIR ATTORNEY one position to the other. I

It is therefore, an object of our invention to provide a United States Patent 5 2,833,885 ELECTRICAL RELAYS Wesley B. Wells and Russell M. Adkins, Wilkinsburg, Pm, assignors to .Westinghouse Air Brake Company, Wilmerding, Pa., a corporation of Pennsylvania M Application October 25, 1954, Serial No. 464,236

11 Claims. (or. 200- 104 Our invention relates to electrical relays, and particularly to a novel means for operatively connecting the movable contacts of an electrical relay with the movable armature. L

In previous relays considerable difficulty hasbeen experiencedin operatively connecting the movable contacts of a relay with the movable armature of a relay without having lost mostion between thearmature and the contacts. Over a period of long and extended use it wasi'found that wear in the connections between the movable contacts and the relay armature sometimes caused considerable change in the adjustment of the contacts, and also in the. operation of the relay contacts from novel relay contact drive structure which prevents linkage lost motion.

Another object of our inventionis to provide a novel contactdriver for an electrical relay in which repair and I so that the entire travel of the relay armature is available for motivating the movable contact members.

In describing our invention in detail, reference will be made to the accompanying drawings in which corresponding parts are generally identifiedby corresponding reference characters and in which: L

Fig. 1 is a vertical sectional view showing one form of plug-in relay embodying our invention.

Fig. 2 isa front view of the relay embodying our invention, portions of which are broken away to illustrate to better advantage certain details of construction.

Fig. 3is an isometric view of the contact driver linkage portions of which are broken away to better illustrate certain details'of construction.

Referring to the drawings, the relay comprises a frame movable contact driver of which is free of any lost motion member 1 non-magnetic material, such as die cast aluminum. The frame member 1 consists of a vertical portion portion 36 supports two core members or pole pieces 3 and 4of magnetizable material which are preferably first machined, and then cast into the horizontal portion 36 of the frame member 1. The two pole pieces3 and 4 are L-shaped and are so arranged that the ends 37 ofthe vertical legs of the pole pieces either project above or terminate flush with the upper surface of the horizontal portion 36, of the frame member 1. The upper ends 37 of the L-shaped pole pieces 3 and 4 are subsequently ground to provide a good magnetic circuit contact with a core member 5 which passes through and supports an ice energizing coil 2. The core member 5 is secured to the portion 36 of the frame member 1 and against the upper ends 37 of the L-shaped pole pieces 3 and 4 by cap screws 38. The L-shaped pole pieces 3 and 4 are so cast within the frame portion 36 that a space or gap is formed between the adjacent inner ends 66 of the horizontal legs of the pole pieces 3 and 4. This space is filled with the non-magnetic material of the frame.

An armature 6 is pivotally secured to the vertical portion 35 of the frame member 1 by a suitable hinge construction comprising a support block 8 and three hinge springs 7. One of the hinge springs is vertically disposed to prevent vertical displacement of the armature 6 and is secured at its lower end to the support block 8 j by screws 8a. The upper end of the vertical hinge spring -7 is secured to one end of the armature 6 by the screws 6a. The other two hinge springs Tare horizontally disposed on'opposite sides of the vertical spring 7 to prevent horizontal displacement of the armature 6. The inner ends of the two springs are secured to the top surface of the support block 8 by screws 8b and a retainer 8c, while the other ends are secured to the bottom surface of the armature 6 by screws 6b. The block 8 is secured to the vertical portion 35 of the frame member 1 by support block adjusting screws 9 passing through enlarged open ings 76 in the frame member 1 and threaded into suit- With able screw openings 8d in the support block 8. this arrangement the armature air gap between the horizontal legs. of the pole pieces 3 and 4, in the frame 1, r

and armature 6 may be adjusted by shifting the armature support block 8 vertically along the portion 35. The armature 6 underlies and cooperates with the pole pieces 3 and 4.

Supported by the pole piece 4 is a permanent magnet 11. secured to the pole piece 4 by magnetizable bolts 39 which also act as a shunt to prevent the demagnetization of the magnet 11, if the magnet is subjected to any stray g ing of substantially hard insulating material which supports two electrical prongs 67 at the rear end thereof,

This arrangement eliminates the necessity of passing coil lead-in wires into the enclosed area of the relay contacts (which will hereinafter be described) and then through the vertical portion 35 of the frame 1. Located between the coil 2 and the core member 5 within the opening 40 r. is a vibration damper leaf spring 62 which tends to hold the coil firm, thus eliminating excessive movement.

The vertical portion 35 of the frame member 1 is provided with a rearwardly facing terminal receiving opening,

72 for receiving the plug-in ends of the fixed contact members 43, the contact base members 54 and indexing pins 73. Located within the vertical portion 35 of the frame member 1, and opening into the treminal opening 72, is a contact block opening 33. Secured by suitable bolts 71 to the portion 35 and extending into the contact block opening 33 is contact support block or member 16 made of suitable insulating material. port block 16 is provided with a plurality of openings 42 for receiving the ends of the fixed contact members 43 and movable contact base members 54. Each of the contact members 43 is provided with a reinforcing rib 45 and g a contact point member 14. Each of the movable con- Patented May 6, 1958 hold-down pole piece member 10 secured by means of secrews 12 to a The permanent magnet 11, is

The contact sup- 1 3 taettbase members 54-:has-secured thereto, movable contact leafmembers 44-0f..springzmaterial..inaimanner dee. scribed hereinafter.

Attached to the movable armature 6 by a securing block 47 isa- U-shapedcontact actuatorsdrive-wire 48. The-U1-shapeddrive =wire- 48. is -.disposed with'.itshorizontal portionpassing through an.;opening.19 in the; securing .block:-47"with its ends extending-downwardly. from the seeuring.;block .47 and armature 6. Thetwo'. downwardlytextendingends of .the drive wire 43.:are. secured sto acontact actuating member 15. The contact actuating member is .ofinsulating-material, and con"- prises .two vertical members 49 of U-shaped cross section which areheld in a spacedapart parallel relationship by-integral vertically spaced apart horizontal pim -76 (see-1Fig.-'3). Thedepending ends of the drive wire (-48 pass through: groovesor channels 53. formed in the I U-shaped or channel members 49 and are turned-upwardly as at 68 10 engage the lower portion of the members 49. Extendedoutwardly from each of the vertical members 49 are integral projecting pins 52. Atthe upperend ofeaeh of the U-shaped members 49 is an enlarged spring seat 50 and avertically extending smaller spring guide 51. At -the lower'end of each of the vertical U-shaped members 49-are contact actuator drive wire slots 69for receivingthe up-turned ends 68 of the drive wire 48.

Surrounding the two downwardly extending portions of. the. actuator drive -wire 48, between the drive wire securing-block47 and-the upper ends of the-U-shaped members-490i the 'member 15, are two actuator pressuresprings 20; The pressure springs 20 act to forcethe actuating member away from -thearmature 6 and downagainst the hooked portions 68 of the-drive wire 48:-

Referring to the contacts,- each of the movable contact base members 54 has secured thereto -on opposite sides thereof oneend -each of two movablecontact tact members 55 and the unsecured'ends ofthe leaf spring; members 44 are transverse grooves 13. When the memhers-44 are inserted between adjacent pairs of movable contact projecting-pins 52, or between adjacent pairsof horizontal pins '70, of the member 15, the transverse grooves 13 of the leaf spring members 44 engage the pins 52 or 70 firmly. In order for the contact leaf spring members 44 to pass between-the projecting pins 52, or-

horizontal pins 70,- of the member 15, the leaf spring members must becompressed. This causes the unsecured ends of the contact leaf spring members 44 to come into-- contact -with-each other and helps to cause'each of the transverse grooves 13 of the members 44 to seat against the movable contact projecting pins 52 or horizontal pins 70'of the member 15. This eliminates all lost-motion between the member 15 and-the leaf spring member 44 as well as placing-the leaf spring members 44 under-an initial pressure forreducing contact bounce.-

Located with a groove 57 adjacent the peripheral edge of the framemember 1 is a gasket or filler memher--58. The gasket or filler member 58 is arranged to cooperate witha transparent cover member 17 to provide a weather-tight seal for the relay contacts.;- The cover-- member--17-is secured to the frame member lby suitable bolts 59. It will 'benoted-that the cover member-is provided with a projecting edge which fits within the gasket member SS-providing-a better seal.

videdwitha latch member 24-.for .holding the.plug,in..re-..-

lay in place on a typical mounting base. The mounting base is not shown since it forms no part of our present invention. A typical mounting base is shown in the copending application Serial Number 459,970 to Harry E. Ashworth filed October 4,. 1954,v for Electrical Relays.

Secured to the forward end of the relay frame 1, as by bolts 65, is a relay handle member.31 provided with finger grip loops 63..and 64 for handling the relay while. plugging it intoor removing it from the-.mountingbase Upon energizatiomof .thev 'relay. coil 2,5 the :-free. end of the armature 6 is pulled upwardly to its attracted position in whichthe core pin-77 engages the pole pieee 4. Movement of the armature to its attracted position lifts the contact actuator member 15, and movable contact leaf spring members 44 to thereby close the front contacts of the relay. It will be noted that the front contacts are :made beforethe core: pin-77 strikes thepole piece 4.; This-causesathenbowed :leaf springs supportingtthe front:;contacts 55to-lbe compressed, thus holding-theta front contacts 55 firmly together against the fixedwcony tacts 14. .g

supporting .-the -back-;contacts 55 to be compressed, thus holding the back contactsq55 firmly against the fixed coms tacts 14.

Therelay of- OUTlIlYEHfiOIlnhQS the advantagewofsposi.

tive contact actionswithout, the introduction: of-lostmotion'.

in the linkage between the. contacts and the.=armature, andthe advantage of a reduction in the number'of :wear points inthecontact, actuating linkage:

Although we have herein shownzandndescribed .only-r one form; ,of. relay :1 embodying .iour 'invention it is :to .be

understoodthat various changes: and: modifications, may? be made within the scope of the appended claims: Will-'11.- ou't departing from the spirit and scope of our invention;-

Having thus described our invention, whatwe-claim 3. l. 4 A :contaet actuating linkage: for interconnecting: a

movable contact actuating member s and ;a :plura-litys-of movable contacts comprising .;an insulated movable; con:

contact: actuating :means .to, said. contact: actuating mem=- her, and resilient means located-betweensaid-contact acr: tuating member,- and said contactiactuating means :for

tensioning said flexible/means toeliminate allilostrmqtion-z;

between said: contact actuating member and-said :contact actuatingmeans;

2. Ina relay having, a movable means,,a-contactactu-. ating structure, comprising ,an insulated movable: contact actuating member having-a plurality of horizontallyexr. tending pairs of spaced apartinsulated"pins;aplurality,

ofresilient leaf spring members disposed in pairs and provided withopposed transverse; grooves, the .members of eachpair being biased apart; by theinpwn resiliency and extending between an associated rp i of. said insulated; pins ,with the opposed; .grooves 'receiying said insulated pins,;drivemeans for connectingsaidmovable-means to. saideontaet actuating. member, and ;resilient means sbias ing saidcontact actuating member infspaced .rela'tiomfro ma saidmovable means said drive means :and said resilient means-providing .an incrementof; movement ofsaid con-itact' actuatingmemberfor every: increment I oi?v movement of said-movable means.

3. In a relay-having -a movable annature,--acontacb actuating structure comprising; a pluralityor pairs of opposed biased apart resilient movable contact leaf spring members, a movable contact actuating member provided with a plurality of horizontally extending pairs of insulated pins, the leaf spring members of each opposed pair being provided with opposed transverse grooves which receive the insulated pairs of an opposed pair of pins in such manner that the spring members are held in compression by the pins, and drive means for connecting said armature to said contact actuating member, said drive means providing proportional movement of said contact actuating member for every increment of movement of said armature.

4. A contact actuating linkage comprising, a plurality of movable contacts, a drive wire securing block having a groove in its upper surface, a movable contact actuating member, drive wire means received within said groove of said securing block for connecting said securing block to said movable contact actuating member, and means surrounding said drive wire and cooperating with said block for constantly urging said drive wire firmly into said groove.

5. In a relay, a contact actuating structure comprising a movable member, a plurality of movable contacts, an insulated movable contact actuator, drive wire means for connecting said movable member to said movable contact actuator, said drive wire means being secured to said movable member through a drive wire securing block provided with a transverse groove in its upper surface for receiving said drive wire, means for securing said drive wire securing block to said movable member, and resilient means located between said securing block and said contact actuator for, eliminating all lost motion due to wear.

6. In a relay, a contact actuating structure comprising, an armature, a plurality of movable contacts operable by a movable contact actuator and a drive wire which is secured to said armature through a drive wire securing block having an upper surface provided with a transverse groove for receiving said drive wire, means for securing said drive wire securing block to said armature, and spring means surrounding said drive wire between said drive wire securing block and said contact actuator for eliminating all lost motion between said armature and said contact actuator.

7. In a relay, a contact actuating structure comprising an armature, a plurality of opposed biased apart resilient movable contact leaf spring members disposed in pairs, an insulated movable contact actuating member provided with a plurality of horizontally extending pins disposed in pairs and retained in spaced apart relationship by two vertically positioned channel members, said opposed pairs of leaf spring members being provided with opposed transverse grooves for receiving while being compressed said opposed pairs of horizontal pins, drive means for connecting said armature to said contact actuating member, and coil spring means compressed between said contact actuating member and said armature for eliminating all lost motion between said armature and said movable contacts.

8. A contact actuating linkage comprising, a drive wire securing block, a U-shaped drive wire provided with the horizontal portion of its U secured to said securing block with the ends of its U extending downwardly away from said securing block, a movable contact actuator, said ends of said drive wirc being passed downwardly through said contact actuator and secured to said actuator, and pressure means located between said securing block and said actuator for urging said securing block and said actuator away from each other to eliminate all lost motion between said securing block and said actuator.

9. A contact actuating linkage comprising a drive wire, a drive wire securing block provided with a transverse slot in its upper surface and two downwardly facing spring receiving recesses in its lower surface, a movable contact actuator, provided with a plurality of horizontally extending pairs of insulated pins held in spaced apart relationship by two spaced apart vertically positioned channel shaped members provided with spring seats at their upper ends, springs located between said upper ends, springs located between said upper ends of said vertically positioned channel members and said downwardly facing spring receiving recesses, said drive wire extending downwardly through said springs and through said vertically positioned channel shaped members and provided with upturned ends for engaging said vertical channel shaped members, said drive wire means and said springs acting as a positive drive means between said securing block and said movable contact actuator for eliminating all lost motion. 7

10. In a relay, a contact actuating linkage comprising a drive wire, a movable contact actuator and a drive wire securing block, said drive wire securingblock being provided with a transverse slot in its upper surface and two downwardly facing spring receiving recesses in its lower surface, springs located between said contact actuator and said drive wire securing block, said drive wire extending downwardly through said springs and provided with upturned ends for fixedly engaging said contact actuator, said drive wire and said springs actingas a positive drive means between said securing block and said contact actuator for eliminating all lost motion.

11. In a relay provided with a frame, an armature pivoted to said frame, fixed contact and a movable contact, a movable contact actuating linkage comprising, a drive wire securing block, a movable contact actuator, and a drive wire for connecting said securing block to said contact actuator, coil spring means surrounding said drive wire for continually urging said contact actuator away from said securing block for eliminating all lost motion in said linkage.

References Cited in the file of this patent UNITED STATES PATENTS 329,399 Leggo Oct. 27, 1885. 1,766,611 Day June 24, 1930 2,258,122 Merkel Oct. 7, 1941 2,273,545 Van Valkenburg Feb. 17, 1942 2,335,110 Dann Nov. 23, 1943 2,347,834 Livingston May 2, 1944 2,490,280 Rees Dec. 6, 1949 2,619,569 Savage .1..... Nov. 25, 1952 2,638,514 Martin May 12, 1953 

